IRF IRPT2061A

PD 60120
IRPT2061A
PRELIMINARY
™
Power Module for 1.5 hp Motor Drives
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1.5 hp (1.1 kW) power output
Industrial rating at 150% overload for 1 minute
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380-480V AC input, 50/60 Hz
3-phase rectifier bridge
3-phase, short circuit rated, ultrafast IGBT inverter
HEXFRED ultrafast soft recovery freewheeling diodes
Brake IGBT and diode
Low inductance (current sense) shunts in
positive and negative DC rail
NTC temperature sensor
Pin-to-base plate isolation 2500V rms
Easy-to-mount package
Case temperature range -25oC to 125oC operational
Figure 1. IRPT2061A Power Module
380-480V
3-phase input
IRPT2061A
Power
Assembly
Gate
Driver
Board
PWM
generator
PWM
variable
frequency/
voltage
isolated
feedback
feedback
processing
keyboard
External Control Functions
Figure 2. The IRPT2061A power module within
a motor control system
AC
motor
IRPT2061A
The IRPT2061A Power Module
The IRPT2061A power module shown in Figure 1 is a
chip and wire epoxy encapsulated module. It houses input
rectifiers, brake IGBT and freewheeling diode, output
inverter, current sense shunts and NTC thermistor. The 3phase input bridge rectifiers are rated at 1600V. The brake
circuit uses 1200V IGBT and freewheeling diode. The
inverter section employs 1200V, short circuit rated ultrafast
IGBT's and ultrafast freewheeling diodes. Current sensing is
achieved through 45 mΩ low inductance shunts provided in
the positive and negative DC bus rail. The NTC thermistor
provides temperature sensing capability. The lead spacing
on the power module meets UL840 pollution level 3
requirements.
page 2
The power circuit and layout within the module are
carefully designed to minimize inductance in the power
path, to reduce noise during inverter operation and to
improve the inverter efficiency. The driver board required
to run the inverter can be soldered to the power module
pins, thus minimizing assembly and alignment. The power
module is designed to be a heat sink with two screw mount
positions, in order to insure good thermal contact between
the module substrate and the heat sink.
IRPT2061A
Specifications
PARAMETERS
VALUES
C O N D IT IO N S
In p u t P o w e r
Voltage
F re q u e n c y
3 8 0 V A C , -1 5 % , 4 8 0 V + 1 0 % , 3 -p h a s e
50/60 H z
C u rre n t
4 .4 A r m s @ n o m in a l o u tp u t
IFS M
400A
T A = 4 0 o C , R th S A = 1 . 4 0 6 o C / W
1 0 m s h a lf-c y c le , n o n -r e p e titiv e s u r g e
O u tp u t P o w e r
Voltage
0 - 480V rms
N o m in a l m o to r h p (k W )
1 .5 h p ( 1 . 1 k W ) n o m i n a l fu ll lo a d p o w e r
1 5 0 % o v e r lo a d fo r 1 m in u te
N o m in a l m o to r c u rre n t
3 .1 A r m s n o m in a l fu ll lo a d p o w e r
4 .6 5 A 1 5 0 % o v e r lo a d fo r 1 m in u te
d e fin e d b y e x te r n a l P W M c o n tr o l
V in = 4 6 0 V A C , fp w m = 4 k H z , fo = 6 0 H z ,
T A = 4 0 o C , R th S A = 1 . 4 0 6 o C / W
D C Lin k
D C lin k v o lta g e
8 5 0 V m a x im u m
B ra k e
C u rre n t
5 .6 A
S en sor
Temp. sense resistance
5 0 kO hm s ± 5 %
3 .1 k O h m s ± 1 0 %
@ T N TC = 2 5 oC
@ TN TC = 1 0 0 oC
C u rre n t se n se
45mO hms ±4%
@ TSH U N T = 2 5 oC
P ro te c tio n
IG B T s h o r t c irc u it tim e
10 µs
R e c o m m e n d e d s h o r t c irc u its h u td o w n c u rre n t
14A peak
DC bus = 850V, VGE = 15V, line to line short
G a te D riv e
QG
5 3 n C (ty p ic a l)
R e c o m m e n d e d g a te d riv e r
IR 2 2 3 3 ( r e fe r F ig u r e 9 )
@ VGE = 15V, refer Figure 4b
M o d u le
Is o la tio n v o lta g e
2500V rms
O p e ra tin g c a s e te m p e ra tu re
-2 5 o C to 1 2 5 o C
M o u n tin g to rq u e
1 Nm
S to ra g e te m p e ra tu re ra n g e
-4 0 o C to 1 2 5 o C
S o ld e r in g te m p e r a tu r e fo r 1 0 s e c .
2 6 0 oC m a x im u m
p in -to -b a s e p la te , 6 0 H z , 1 m in u te
9 5 % R H m a x . (n o n -c o n d e n s in g )
M 4 s c re w ty p e
a t th e p in s (.0 6 " fr o m c a s e )
page 3
RthSA 100% load
(continuous) 10-60 Hz
Power
150%
1.5 hp
(1.1 kW)
Power
100%
Power
150%
RthSA 150% load
(1 min.) down to 3 Hz
Total Power Dissipation (Watts)
Thermal Resistance (RthSAoC/W)
IRPT2061A
RthSA 150% load
(1 min.) 10-60 Hz
RthSA 100% load
(continuous) 10-60 Hz
1hp
(0.74 kW)
Power
100%
Power
150%
RthSA 150% load
(1 min.) 10-60 Hz
Total Power Dissipation (Watts)
Thermal Resistance (RthSAoC/W)
Figure 3a. 1.5hp/3.1A Output Heat Sink Thermal Resistance and Power Dissipation vs. PWM Frequency
(Induction Motor Load)
RthSA 150% load
(1 min.)
down to 3Hz
Figure 3b. 1hp/2.2A Output Heat Sink Thermal Resistance and Power Dissipation vs. PWM Frequency
(Induction Motor Load)
NOTE: For Figures 3a and 3b: Operating Conditions: Vin = 460Vrms, MI = 1.15, PF-0.8, TA = 40oC, Ti = 145oC, TS = 95oC,
ZthSA limits ∆Tc during 1 minute overload to 10oC
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IRPT2061A
Figure 4a. Typical Capacitance vs
Collector-to-Emitter Voltage of the IGBT
Figure 4b. Typical Gate Charge vs
Gate-to-Emitter Voltage of the IGBT
TJ = 150oC
TJ = 25oC
Figure 4c. Typical Transfer Characteristics
of the IGBT
Figure 5. Nominal R-T Characteristics of the
NTC Thermistor (YNE503J01TR)
page 5
IRPT2061A
Mounting Procedure
Mounting
Power Connections
1. Connect the driver board and the IRPT 2061A power
module.
2. Remove all particles and grit from the heat sink and
power substrate.
3. Spread a .004" to .005" layer of silicone grease on the
heat sink, covering the entire area that the power substrate
will occupy. Recommended heat sink flatness in .001 inch/
inch and Total Indicator Readout (TIR) of .003 inch below
substrate.
4. Place the power substrate onto the heat sink with the
mounting holes aligned and press it firmly into the silicone
grease.
5. Insert the two M4 mounting screws through the PCB,
power substrate and into the heat sink and tighten the screws
to 1 Nm torque, according to the sequence shown in Figure 6.
The power module pin designation, function and other
details can be obtained from the package outline in Figure 7
and circuit diagram in Figure 8. Three phase input
connections are made to pins R, S and T and inverter output
connections are made to pins U, V and W. Positive DC bus
and brake IGBT collector connections are brought out to
pins P and BR respectively. Positive rectifier output and
positive inverter bus are brought out to pins BP and P
respectively in order to provide DC bus capacitor to pins
IS1, IS2 and IS3, IS4 on the positive and negative DC rails,
respectively.
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Figure 6. Power Module Mounting Screw Sequence
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IRPT2061A
NOTE: Dimensions are in inches (millimeters)
Figure 7a. Power Module Package Outline
page 7
IRPT2061A
Figure 7b. Power Module Package Outline
page 8
IRPT2061A
Figure 8. Power Module Circuit Diagram
Figure 9. Recommended Gate Drive Circuit
page 9
IRPT2061A
Functional Information
Heat Sink Requirements
Over Temperature Protection
Figures 3a through 3b show the thermal resistance of the
heat sink required for various output power levels and pulsewidth-modulated (PWM) switching frequencies. Maximum
total losses of the unit are also shown. This data is based on
the following key operating conditions:
• The maximum continuous combined losses of the
rectifier and inverter occur at full pulse-width-modulation.
These losses set the maximum continuous operating
temperature of the heat sink.
• The maximum combined losses of the rectifier and
inverter at full pulse-width modulation under overload set
the increment temperature rise of the heat sink during
overload.
• The minimum output frequency at which full load
current is to be delivered, sets the peak IGBT junction
temperature.
• At low frequency, IGBT junction temperature tends to
follow the instantaneous fluctuations of the output current.
Thus, peak junction temperature rise increases as output
frequency decreases.
Over temperature can be detected using the NTC
thermistor included in the power module for thermal
sensing. Protection circuit that initiates a shutdown if the
temperature of the IMS substrate exceeds a set level can be
implemented. The nominal resistance vs. temperature
characteristic of the thermistor is given in Figure 5.
page 10
Voltage Rise During Braking
The motor will feed energy back to the DC link during
regenerative braking, forcing the bus voltage to rise above
the level defined by the input voltage. Deceleration of the
motor must be controlled by appropriate PWM control to
keep the DC bus voltage within the rated maximum value.
For high inertial loads, or for very fast deceleration rates,
this can be achieved by connecting an external braking
resistor across P and BR and controlling the brake IGBT
switching when the bus voltage exceeds the allowable limit.
IRPT2061A
Part Number Identification and Ordering Instructions
IRPT2061A Power Module
Chip and wire epoxy encapsulated module with 1600V
input rectifiers, 1200V brake IGBT and freewheeling diode,
1200V short-circuit rated, ultrafast IGBT inverter with
ultrafast freewheeling diodes, temperature sensing NTC
thermistor and current sensor low inductance shunts.
page 11
IRPT2061A
WORLD HEADQUARTERS: 233 Kansas St., El Segundo, California 90245, Tel: (310) 322 3331
EUROPEAN HEADQUARTERS: Hurst Green, Oxted, Surrey RH8 9BB, UK Tel: ++ 44 1883 732020
IR CANADA: 7321 Victoria Park Ave., Suite 201, Markham, Ontario L3R 2Z8, Tel: (905) 475 1897
IR GERMANY: Saalburgstrasse 157, 61350 Bad Homburg Tel: ++ 49 6172 96590
IR ITALY: Via Liguria 49, 10071 Borgaro, Torino Tel: ++ 39 11 451 0111
IR FAR EAST: 171 (K&H Bldg.), 3-30-4 Nishi-ikebukuro 3-Chome, Toshima-ku, Tokyo Japan Tel: 81 3 3983 0086
IR SOUTHEAST ASIA: 315 Outram Road, #10-02 Tan Boon Liat Building, Singapore 0316 Tel: 65 221 8371
http://www.irf.com/
Data and specifications subject to change without notice.
5/98
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